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SALES DIVISION NETWORK TECHNICAL INFORMATION WORKSHOP MANUAL

SALES DIVISION NETWORK TECHNICAL INFORMATION

WORKSHOP

MANUAL

SALES DIVISION NETWORK TECHNICAL INFORMATION WORKSHOP MANUAL
SALES DIVISION NETWORK TECHNICAL INFORMATION WORKSHOP MANUAL

CONTENTS

CONTENTS CONTENTS CHARACTERISTICS Engine Capacities Chassis markings Engine markings Frame Dimensions and weight Tyres SERVICE SCHEDULE AND COMMISSIONING Check Change Check and lubricate Reading the ECU fault codes Test machine SPECIAL IMPORTANT POINTS Oil and fuel Starting up after overhauling the engine Electricity Special features TIGHTENING TORQUES Body panels Frame Standard SPECIAL TOOLS INSTRUMENT CLUSTER Instrument cluster description Description of the multi-function display MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS Changing from the total distance display to the daily display Changing the distance unit Setting the clock Maintenance function Fuel gauge self-diagnostic CONTROL CABLE AND HARNESS ROUTINGS ABS/PBS panel Conventional braking panel Right-hand side 50 cc Left-hand side 125 cc Rear right Rear centre LOCATION OF COMPONENTS 50 cc 125 cc BODY Location of body components (50 and 125 cc) Body component sequence of disassembly (50 and 125 cc) Removal of front lower legshields (50 and 125 cc) Procedure 1 Removal of the headlight and sidelight assemblies (50 and 125 cc) Method for fitting the lower legshield bracket (50 and 125 cc) Page : 2

and side light assemblies (50 and 125 cc) Method for fitting the lower legs hield bracket

2

5

 

5

5

5

5

6

6

6

7

 

7

7

7

7

7

8

 

8

8

8

8

9

 

9

9

9

10

11

 

11

12

12

 

12

13

13

14

14

15

 

15

15

16

17

18

18

19

 

19

20

21

 

21

21

22

22

22

 
 

CONTENTS

Removal of the storage compartment (50 and 125 cc) Procedure 2

23

Removal of the shield)(50 and 125 cc) Procedure 3

23

Removal of the rear cover assembly and mudflap (50 and 125 cc) Procedure 4

25

Removal of the rear light / storage compartment trim (50 and 125 cc)

25

FRAME

26

Removal of the rear frame (50 cc)

26

Removal of the frame (50 cc)

27

MISCELLANEOUS OPERATIONS

29

Removal of the oil tank (50 cc) or oil separator (125 cc), the saddle lock (50 and 125 cc)

29

To remove the oil filter (50 cc)

29

To remove the header tank (50 and 125 cc)

29

Removal of the radiator / radiator bracket (50 and 125 cc)

30

Removal of the fuel gauge (50 cc)

31

Removal of the strainer (50 cc)

32

Removal of the fuel tank filler ring (50 and 125 cc)

33

Removal of the fuel tank (50 cc)

33

Removal of the central shock absorber / from the swingarm (50 and 125 cc)

34

Removal of the radiator deflector (50 cc)

35

Removal of the braking limiter (50 cc)

35

Removal of the saddle strut (50 and 125 cc)

35

WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE (50 cc)

36

Removal of the inlet coupling and valves

36

To remove the cylinder head Procedure 5

37

Removal of the cylinder / piston

37

Removal of the temperature sensor

38

Removal of the air compressor

38

SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE

39

Procedure for reducing the fuel circuit pressure Procedure 6 (50 cc)

39

Procedure for bleeding the fuel circuit Procedure 7 (50 and 125 cc)

39

Removal of the injection manifold (50 cc)

40

Removal of the air injector (50 cc)

40

Removal of the thermostat (50 cc)

41

Removal of the ECU (50 and 125 cc)

42

Removal of the throttle unit (50 cc)

42

Removal of the oil pump (50 cc)

43

Removal of the fuel gauge (50 cc)

43

ELECTRICITY

44

Removal of the instrument cluster (50 and 125 cc)

44

Removal of the voltage regulator and saddle actuator (50 and 125 cc)

44

Removal of the battery cover, battery, fuses (50 and 125 cc)

44

Removal of the starter motor and/or lighting relay (50 and 125 cc) and/or the fuel pump and/or ABS/PBS system relay (125 cc)

45

Removal of the high tension coil (50 and 125 cc)

45

Removal of the horn, immobiliser module (50 and 125 cc)

45

Removal of the transponder antenna (50 and 125 cc)

46

Removal of the starter motor (50 cc)

46

ENGINE REMOVAL

47

Removal of the 50 cc engine

47

125 cc SPECIFIC MISCELLANEOUS WORK

48

Removal of the idle valve

48

Removal of the thermostat

48

125 cc SPECIFIC MISCELLANEOUS WORK 48 Removal of the idle valve 48 Removal of the thermostat

Page : 3

CONTENTS

Removal of the engine temperature sensor

57

48

Removal of the fuel injector

49

Removal of the oil pressure switch

49

Removal of the throttle unit

49

Removal of the fuel pump / of the fuel gauge

51

Removal of the starter motor

52

Removal of the rear brake pads or caliper

53

Removal of the suspension arm

53

Removal of the engine mounting twin linkrod

54

Method of fitting the engine mounting twin linkrod

55

Removal of the motor-driven fan heat switch

56

Removal of the motor-driven fan

56

125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL

Removal of the power unit Procedure 8

57

Removal of the engine Procedure 9

58

Removal of the rocker cover, setting the rockers, removal of the camshaft, removal of the rockers

58

Removal of the cylinder head, removal of the cylinder and/or piston, removal of the cylinder head or base gasket, removal of the timing chain, setting the timing

58

Removal of the connecting rod and/or LH bearing and/or changing the casings

58

Page : 4

setti ng the timing 58 Removal of the connecting rod and/or LH bearing and/or changing the

CHARACTERISTICS

CHARACTERISTICS

Engine

 

50 cc

125 cc

Type

Single cylinder 2-stroke direct injection

Single cylinder 4-stroke indirect injection

Cooling

Liquid

Bore x stroke

39.9 x 39.8 mm

57 x 48.9 mm

Cubic capacity

49.9 cc

124.8 cc

Max. power

3.6 kW at 7500 rpm

9.2 kW at 8750 rpm

output

Max. torque at

6500 rpm

7250 rpm

Fuel system

Direct electronic injection (TSDI)

Indirect electronic injection (EFI)

Lubrication

Electric oil pump

Trochoidal pump

Transmission

2 variable pulleys and Vee belt

Clutch

Centrifugal automatic

Spark plug

NGK CPR8E

NGK CR7EB

Exhaust

Catalytic

Non-catalytic

Capacities

Fuel tank

8 litres 95 or 98 lead-free

Oil tank

1.2 litres semi-synthetic (API TC)

 

Engine oil

 

1.25 litres SAE 10W40

Relay box oil

0.12 litres SAE 80W90 Life lubricated

Coolant*

1.3 l

1.6 l

Fork

125 cc by tube Esso Univis 46 or Agip H Lift 46

190 cc by tube Esso Univis 46 or Agip H Lift 46

* Peugeot coolant part number 754614

Chassis markings

46 * Peugeot coolant part number 754614 Chassis markings 1 – VIN number and manufacturer’s plate

1 – VIN number and manufacturer’s plate

Engine markings

number 754614 Chassis markings 1 – VIN number and manufacturer’s plate Engine markings 2 – Engine

2 – Engine number

number 754614 Chassis markings 1 – VIN number and manufacturer’s plate Engine markings 2 – Engine

Page : 5

CHARACTERISTICS

Frame

 

50 cc

125 cc

Frame

 

Direct Perimetric Frame

 

Front suspension

Ø 32 mm telescopic fork

Ø 36 mm telescopic fork

Travel

85

mm

95

mm

Rear suspension

 

Central shock absorber

 

Travel

95

mm

90

mm

Dimensions and weight

Overall length

1914

mm

1918

mm

Width at

 

handlebar

 

740 mm

 

Height with rear view mirror

1260

mm

1279

mm

Wheelbase

1314

mm

1369

mm

Ground clearance

137

mm

112

mm

Saddle height:

820

mm

845

mm

Unladen weight

115 kg

149 kg

Tyres

Front wheel

13-inch alloy

Front tyre

130/60 - 13

Front tyre

2 bar

2 bar

pressure

Rear wheel

13-inch alloy

Rear tyre

130/60 - 13

140/60 - 13

Rear tyre pressure

2.2 bar

2.2 bar

Page : 6

wheel 13-inch alloy Rear tyre 130/60 - 13 140/60 - 13 Rear tyre pressure 2.2 bar

SERVICE SCHEDULE AND COMMISSIONING

SERVICE SCHEDULE AND COMMISSIONING Heavy duty servicing is for vehicles used under “harsh” conditions: door-to-door deliveries, intensive urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C.

Service operations

500

kms

Every 5000 kms or 12 months

Every 10000 kms

or 1 months

Heavy duty servicing

500

kms

Every 2500 kms

Every 5000 kms

Check

Throttle cable play

 

X

X

X

Steering column play

 

X

X

X

Operation of electrical equipment

 

X

X

X

Condition of front and rear brake hydraulic controls

 

X

X

X

Condition of fuel pipes

 

X

X

X

Condition of oil pipes

 

X

X

X

Tyre pressures

 

X

   

Tyre condition, pressure and wear

 

X

X

Brake fluid level

 

X

X

X

Battery electrolyte level *

 

X

X

X

Coolant level

 

X

X

X

Engine oil level

 

X

   

Tightness of nuts and bolts

 

X

X

X

Change

Spark plug

 

X

X

Inlet silencer/air filter**

     

Front brake pads#

   

X

Rear brake pads *#

   

X

Drive pulley bearings and guides #

 

X

X

Transmission belt

   

X

Engine oil (+ clean strainer)

 

X

 

Engine oil filter

   

X

Brake fluid and coolant**

     

Check and lubricate

Driven pulley: moving flange and needle bush

   

X

Drive pulley: moving flange and rollers*

   

X

Reading the ECU fault codes

Injection and ABS/PBS system*

 

X

X

X

Test machine

On road

 

X

X

X

* depending on equipment # if necessary ** every 20000 km for the 50 cc (10000 if harsh use servicing) and every 40000 for the 125 cc (20000 km if harsh use servicing)

km for the 50 cc (10000 if harsh use servicing) and every 40000 for the 125

Page : 7

SPECIAL IMPORTANT POINTS

SPECIAL IMPORTANT POINTS

Oil and fuel This engine is designed to run on 95 or 98 unleaded fuel only Never run the machine with a petrol/oil mixture. The oil used for the separate lubrication system is « Esso 2T Spécial » or « Esso 2T Spécial anti- fumée » recommended by the manufacturer

Starting up after overhauling the engine The oil circuit bleed system (50 cc) must be checked with the diagnostic tool, the fuel pump bleeds itself automatically when the ignition is turned on Starting should not be with a 2-stroke mixture, as the fuel pump and injectors are not designed to operate with oil. When starting the engine hot or cold do not accelerate Check the coolant level in the header tank After road-testing the machine, check there are no fault codes left in the ECUs (read with diagnostic tool)

Electricity All components of the electrical system are powered with 12 volts DC. The battery must not be disconnected while the engine is running and the voltage must be at least 8.5 volts for the ECU to function and enable engine starting

To avoid any risk of forgetting to turn off the ignition after opening the saddle, the ignition key should be removed after each job

Special features After changing the injection ECU or the throttle, the initialisation procedure must be carried out with the diagnostic tool The ECU has a diagnostic function which via the instrument cluster Led or the diagnostic tool, enables reading of the faults in the memory

The fuel inlet and injection manifold return pipes must only be replaced by genuine service parts. The fuel pressure of 8 bars requires special pipes. The fuel pipes must be changed if they show signs of wear, cracks, etc. The clips are specific, they must always be changed each time they are removed and replaced with new genuine parts clips

Note:

Before carrying out any work, leave the engine to cool for a minimum of 2 hours. Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Work in a clear and well-ventilated area.

Page : 8

not smoke in the working area and avoid proximity to flames or sparks. Work in a

TIGHTENING TORQUES

TIGHTENING TORQUES

Body panels

Front mudguard

0.8

to 1.2 mdaN

Handlebar cover

0.2

to 0.4 m.daN

Front legshields

0.2

to 0.4 m.daN

Rear shield

0.2

to 0.4 m.daN

Bottom panel

0.2

to 0.4 m.daN

Footboard

0.4

to 0.6 m.daN

Saddle storage compartment

0.4

to 0.6 m.daN

Rear panels

0.2

to 0.4 m.daN

Grab handle

2

to 2.5 m.daN

Rear mudguard

0.2

to 0.4 m.daN

Frame

Front wheel spindle

6

to 7 m.daN

Rear wheel bolt

8.5

to 9.5 m.daN

Rear wheel spindle nut

10 to 12 m.daN

Linkrod to engine pivot

4.3

to 5 m.daN

Linkrod to swingarm

4.3

to 5 m.daN

Engine-upper linkrod pivot

4.3

to 5 m.daN

Shock absorber top mount

2.4

to 2.6 m.daN

Shock absorber bottom mount

2.4

to 2.6 m.daN

Front and rear frame mounting nut

2

to 2.5 m.daN

Exhaust to cylinder mounting nut

1.5

to 1.8 m.daN

Exhaust to cylinder head mounting nut (125 cc)

1.5

to 1.8 m daN

Exhaust to casing mounting bolt

2

to 2.5 m.daN

Upper cone (in 2 operations)

3.8/2.3 mdaN

Upper cone locknut

Tighten manually

Steering locknut

7

to 8 m.daN

Front brake caliper

2.5

to 3.5 m.daN

Rear brake caliper

2

to 2.5 m.daN

Front disc brake

0.9

to 1 m.daN

Rear disc brake

0.9

to 1 m.daN

Handlebar

2.5

to 3.5 mdaN

Standard

Nut and bolt 5 mm diameter

0.5

m.daN

Nut and bolt 6 mm diameter

1 m.daN

Nut and bolt 8 mm diameter

2.2

m.daN

Nut and bolt 10 mm diameter

3.5

m.daN

Nut and bolt 12 mm diameter

5.5

m.daN

2.2 m.daN Nut and bolt 10 mm diameter 3.5 m.daN Nut and bolt 12 mm diameter

Page : 9

SPECIAL TOOLS

SPECIAL TOOLS . Tool N° Description Used with 68994 Torque wrench 8 Nm to 54
SPECIAL TOOLS
.
Tool N°
Description
Used with
68994
Torque wrench 8
Nm to 54 Nm
extension
752235
adapter
752236
750539
Tie-wrap pliers
752235
1/2 extension
69802
or
753977
752236
1/2-3/8 adapter
69802
or
753978
753977
Torque wrench
30 Nm to 150
Nm
extension
752235
adapter
752237
754086
Steering tool
755806
Cartridge France
755878
755807
Cartridge Export
755878
755878
Diagnostic tool
755806
(game boy
755807
colour)
755990 Diagnostic tool update software 755996 hose clamp 756017 petrol injection power supply harness 756715
755990
Diagnostic tool
update software
755996
hose clamp
756017
petrol injection
power supply
harness
756715
Tank gauge spanner
756449
ABS/PBS interface
cable for diagnostic
tool
755878
755806
755807
756575
Piston locking fork
756716
Tank ring spanner
756607
Fork seal fitting tool
125 cc
756608
Fork seal fitting tool
50 cc

Page : 10

fork 756716 Tank ring spanner 756607 Fork seal fitting tool 125 cc 756608 Fork seal fitting

INSTRUMENT CLUSTER

INSTRUMENT CLUSTER Instrument cluster description

CLUSTER INSTRUMENT CLUSTER Instrument cluster description 1. Multi-function display 2. Rev counter 3. Speedometer 4.

1. Multi-function display

2. Rev counter

3. Speedometer

4. Engine temperature gauge

5. Control button

6. Injection system diagnostic warning light

7. Transponder immobiliser dissuasion light

8. ABS/PBS system diagnostic warning light (125 cc)

9. Headlight warning light

10. Low oil level (50 cc) or oil pressure (125 cc) warning light

11. Direction indicator warning light

12. Battery charge warning light

When the ignition is turned on, the different functioning tests are carried out automatically for 5 seconds:

- Display of all of the multi-function display items (1) and the speed (3)

- Lighting of all the warning lights (except ABS/PBS depending on version)

- Test of rev counter stepper motors (2) and engine temperature (4) giving one sweep of the needles and zero reset where necessary

stepper motors (2) and engine temperature (4) giving one sweep of the needles and zero reset

Page : 11

INSTRUMENT CLUSTER

Description of the multi-function display

13. Tripmeter (total or daily)

14. Tripmeter display

15. Type of unit used by the tripmeter

16. Clock

17. Maintenance indicator (spanner symbol)

18. Fuel gauge

17. Maintenance indicator (spanner symbol) 18. Fuel gauge MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS Setting and

MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS

Setting and function change operations can only be carried out if the machine is stationary (engine not running) This is for safety reasons.

Changing from the total distance display to the daily display The tripmeter (13) has two functions:

- Total distance (15) displays and memorises the total distance covered by the machine

- The tripmeter (14) displays and memorises the distance covered over a given period

With the ignition on, changeover from the main to the daily distance and inversely is by briefly pressing the control button (5)

and inversely is by briefly pressing the control button (5) With the ignition on, reset of

With the ignition on, reset of the daily tripmeter is by pressing the control button for more than 3 seconds

Page : 12

With the ignition on, reset of the daily tripmeter is by pressing the control button for

INSTRUMENT CLUSTER

Changing the distance unit Changing the distance unit (km or miles) is as follows:

- Ignition off, hold down the control button (5) and turn on the ignition, the distance unit flashes

- Select the unit by briefly pressing the control button, the distance unit changes from “km” to “miles” or inversely. -Turn off ignition to confirm

to “miles” or inversely. -Turn off ignition to confirm Setting the clock The time can only

Setting the clock The time can only be set in the tripmeter total distance position

- Ignition on, press the button (5) until the time flashes

- Set the time by successive pushes on the control button

- To change the tenths of a minute, press the button until the minute tenths flash

- Change the minute tenths by pressing as required on the button

- Proceed in the same way to set the minutes

- Press the button for more than 3 seconds to validate the clock setting

in the same way to set the minutes - Press the button for more than 3
in the same way to set the minutes - Press the button for more than 3

Page : 13

INSTRUMENT CLUSTER

Maintenance function Every 5000 km a « spanner » symbol appears informing the rider that his machine is due for service After servicing the machine, erase the spanner symbol as follows:

- Ignition off, hold down the button (5) and turn on the ignition, the spanner symbol flashes

- Release the control button

- Press the button again for at least 5 seconds, the spanner symbol goes off

again for at least 5 seconds, the spanner symbol goes off Fuel gauge self-diagnostic If the

Fuel gauge self-diagnostic If the fuel system is cut off from the fuel gauge, when the ignition is turned on, the display segments light one after the other

Page : 14

is cut off from the fuel gauge, when the ignition is turned on, the display segments

CONTROL CABLE AND HARNESS ROUTINGS

CONTROL CABLE AND HARNESS ROUTINGS ABS/PBS panel

ROUTINGS CONTROL CABLE AND HARNESS ROUTINGS ABS/PBS panel Conventional braking panel 1. Main harness 2. Throttle

Conventional braking panel

HARNESS ROUTINGS ABS/PBS panel Conventional braking panel 1. Main harness 2. Throttle control 3. Transponder antenna

1. Main harness

2. Throttle control

3. Transponder antenna

4. Speed sensor

5. Brake light switch

6. ABS/PBS brake module reservoir feed pipe

7. Rear brake pipe

8. Right master cylinder to module brake pipe

9. Module brake pipe to front caliper

10. Left master cylinder to module brake pipe

1. Main harness

2. Throttle control

3. Transponder antenna

4. Speed sensor

5. Brake light switch

6. Front brake pipe

7. Rear brake pipe

control 3. Transponder antenna 4. Speed sensor 5. Brake light switch 6. Front brake pipe 7.

Page : 15

CONTROL CABLE AND HARNESS ROUTINGS

Right-hand side 50 cc

CONTROL CABLE AND HARNESS ROUTINGS Right-hand side 50 cc 1. Main harness 2. Throttle cable (50

1. Main harness

2. Throttle cable (50 cc)

3. Transponder antenna

4. Speed sensor

5. Front brake pipe

6. Rear brake pipe

7. Fuel feed pipe

cable (50 cc) 3. Transponder antenna 4. Speed sensor 5. Front brake pipe 6. Rear brake

Page : 16

cable (50 cc) 3. Transponder antenna 4. Speed sensor 5. Front brake pipe 6. Rear brake

CONTROL CABLE AND HARNESS ROUTINGS

Left-hand side 125 cc

CONTROL CABLE AND HARNESS ROUTINGS Left-hand side 125 cc 1. Main harness 2. Throttle cable (125

1. Main harness

2. Throttle cable (125 cc)

3. Rear brake pipe

4. Fuel supply pipe

5. Air pressure slave pipe

6. Fuel overflow pipe

Throttle cable (125 cc) 3. Rear brake pipe 4. Fuel supply pipe 5. Air pressure slave
Throttle cable (125 cc) 3. Rear brake pipe 4. Fuel supply pipe 5. Air pressure slave

Page : 17

CONTROL CABLE AND HARNESS ROUTINGS

Rear right

CONTROL CABLE AND HARNESS ROUTINGS Rear right 1. Main harness Rear centre 1. Main harness Page

1. Main harness

Rear centre

CONTROL CABLE AND HARNESS ROUTINGS Rear right 1. Main harness Rear centre 1. Main harness Page

1. Main harness

Page : 18

CONTROL CABLE AND HARNESS ROUTINGS Rear right 1. Main harness Rear centre 1. Main harness Page

LOCATION OF COMPONENTS

LOCATION OF COMPONENTS 50 cc

LOCATION OF COMPONENTS LOCATION OF COMPONENTS 50 cc 1. Injection ECU 2. Throttle unit 3. Engine

1. Injection ECU

2. Throttle unit

3. Engine position and speed sensor

4. Temperature sensor

5.

6. Fuel injector

7.

8.

9. Immobiliser module

Battery

Air injector

Ignition coil

10. Fuel pump

11. Oil pump

12. Diagnostic light

13. Diagnostic plug

14. Air compressor

15.

16. Voltage regulator

17.

18.

19. Starter / lighting relay

Fuses

Horn

Saddle lock

plug 14. Air compressor 15. 16. Voltage regulator 17. 18. 19. Starter / lighting relay Fuses

Page : 19

LOCATION OF COMPONENTS

125 cc

LOCATION OF COMPONENTS 125 cc 1. Injection ECU 2. Throttle unit 3. Engine position and speed

1. Injection ECU

2. Throttle unit

3. Engine position and speed sensor

4. Temperature sensor

5. Air pressure and air temperature sensor

6. Battery

7. Fuel injector

8. Idle control valve

9.

Ignition coil

10. Immobiliser module

11. Fuel pump

Page : 20

12. Diagnostic light

13. Diagnostic plug

14. Fuel pump relay, ABS/PBS, lighting, 25A fuse

15. Heat switch

16. Motor-driven fan

17. Starter relay, 15 A fuse

18. Voltage regulator

19.

20. Saddle lock

21. ABS/PBS module

22. Vehicle speed sensor and ABS/PBS

Horn

relay, 15 A fuse 18. Voltage regulator 19. 20. Saddle lock 21. ABS/PBS module 22. Vehicle

BODY

BODY Location of body components (50 and 125 cc)

BODY BODY Location of body components (50 and 125 cc) Body component sequence of disassembly (50

Body component sequence of disassembly (50 and 125 cc)

LEGSHIELD TOP FOOTBOARDS RIDER SADDLE PASSENGER PANEL (7) (11) SADDLE AND (1) GRAB HANDLE (15)
LEGSHIELD TOP
FOOTBOARDS
RIDER SADDLE
PASSENGER
PANEL
(7)
(11)
SADDLE AND
(1)
GRAB HANDLE
(15)
WIND
FRONT LOWER
TUNNELS
STORAGE
BATTERY COVER
DEFLECTOR* AND
LEGSHIELDS
(8)
COMPARTMENT
(16)
HANDLBAR
(4)
(12)
FRONT FAIRING(2)
HANDLEBAR
REAR FAIRING (3)
MUDGUARD AND
BELLYPAN
FUEL TANK
REAR FAIRING
FORK GUARD
(9)
FAIRING
AND
(5)
(13)
IMMOBILISER
UNIT (17)
MUDGUARD
LEGSHIELD REAR
MUDFLAP AND
STORAGE
(6)
PANEL
NUMBER PLATE
COMPARTMENT
(10)
PANEL
TRIM PANELS
(14)
(18)

* Depending on model

AND STORAGE (6) PANEL NUMBER PLATE COMPARTMENT (10) PANEL TRIM PANELS (14) (18) * Depending on

Page : 21

BODY

Removal of front lower legshields (50 and 125 cc) Procedure 1

- Remove the ignition key

- Remove the front upper legshield (1) (3 screws)

- Disconnect the lighting and direction indicator connections

- Remove the front lower left legshield (2) (3 screws), including the 2 fixing it to the RH legshield (3)

- Remove the front lower RH legshield (3 screws)

Removal of the headlight and sidelight assemblies (50 and 125 cc)

- Remove the front lower legshields (see procedure 1)

- Remove the headlight and sidelight assemblies (3 screws each)

Method for fitting the lower legshield bracket

(50 and 125 cc)

- Fit the support bracket (1) with its bolt (2) to the frame but do not tighten it

- Fit the lower RH legshield (3) with the fixing screws

- Adjust the support bracket to the legshield and tighten its frame fixing screw

(3) with the fixing screws - Adjust the support bracket to the legshield and tighten its
(3) with the fixing screws - Adjust the support bracket to the legshield and tighten its
(3) with the fixing screws - Adjust the support bracket to the legshield and tighten its

Page : 22

(3) with the fixing screws - Adjust the support bracket to the legshield and tighten its

BODY

Removal of the storage compartment (50 and 125 cc) Procedure 2

- Open the saddle (1)

- Remove the saddle strut upper securing nut

(2)

- Remove the saddle (1) (2 nuts)

- Remove the storage compartment (3) (6 nuts)

Removal of the shield)(50 and 125 cc)

Procedure 3

- Remove the front lower legshields (see procedure 1)

- Remove the storage compartment (see

procedure 2)

- Remove the tank cap trim (1) (3 screws)

- Remove the tank cover (2) (5 screws)

Note: When removing the trim 3 screws, take care not to release the 3 nuts held in place in the tank filler ring

- To remove the footboards (3) (2 screws each)

Method for removing the footboards

- Unclip the outer part of the footboard starting at the rear (A)

- Unclip the footboard from the frame bottom

- Raise the footboard by levering on the front end (B) to release it from the rear shield

from the frame bottom - Raise the footboard by levering on the front end (B) to
from the frame bottom - Raise the footboard by levering on the front end (B) to
from the frame bottom - Raise the footboard by levering on the front end (B) to
from the frame bottom - Raise the footboard by levering on the front end (B) to

Page : 23

BODY

- Remove the tunnels (4) (3 screws each) by

unclipping starting at the rear upper part

- Remove the bottom panels (5) (3 screws)

Page : 24

(4) (3 screws each) by unclipping starting at the rear upper part - Remove the bottom
(4) (3 screws each) by unclipping starting at the rear upper part - Remove the bottom
(4) (3 screws each) by unclipping starting at the rear upper part - Remove the bottom

BODY

- Remove the rear shield (6) (3 screws)

including 1 screw next to the filler cap

Removal of the rear cover assembly and mudflap (50 and 125 cc) Procedure 4

- Remove the storage compartment (see

procedure 2)

- Remove the ignition key

- Remove the passenger seat (2 bolts)

- Remove the rear handle (3 nuts)

- Remove the rear cover (1) 8 fixing screws

- Disconnect the rear light and direction

indicator connections (and number plate light

depending on model)

- Remove the rear cover assembly (unclip the

rear cover from the storage compartment trim, fed one side of the panel under the battery bracket, pull the cover clear by turning it on the same side)

Removal of the rear light / storage compartment trim (50 and 125 cc)

- Remove the rear cover assembly (see procedure

4)

- Remove the rear light

- Remove the storage compartment trim (1) 4

screws

- Unclip the compartment trim from the frame to remove it

- Remove the storage compartment trim (1) 4 screws - Unclip the compartment trim from the
- Remove the storage compartment trim (1) 4 screws - Unclip the compartment trim from the
- Remove the storage compartment trim (1) 4 screws - Unclip the compartment trim from the
- Remove the storage compartment trim (1) 4 screws - Unclip the compartment trim from the

Page : 25

FRAME

FRAME Removal of the rear frame (50 cc)

- Remove the rear cover assembly (see procedure

4)

- Remove the battery cover

- Disconnect and remove the battery

- Unclip the battery bracket harness without disconnecting the components

- Remove the battery bracket (1)

- Remove the 2 storage compartment (2) trim pieces

- Remove the regulator (3), the oil pump (4)

after disconnecting it, and the saddle lock actuator (5)

- Disconnect the oil level low switch (6)

- Remove the oil tank (7)

- Remove the 4 frame fixing nuts and bolts (8)

- Remove the rear frame

- Remove the nuts, the footboard with the caps and the saddle lock from the rear frame

Note: When refitting, the storage compartment trim must be fitted in position before the rear cover panel assembly

The regulator must be connected and its protection fitted before fixing to its bracket

There must be no air bubbles in the feed pipe before connecting it to the oil pump

Check: Using the diagnostic tool, check for fault codes, clear them if necessary

connecting it to the oil pump Check: Using the diagnostic tool, check for fault codes, clear
connecting it to the oil pump Check: Using the diagnostic tool, check for fault codes, clear
connecting it to the oil pump Check: Using the diagnostic tool, check for fault codes, clear

Page : 26

connecting it to the oil pump Check: Using the diagnostic tool, check for fault codes, clear

FRAME

Removal of the frame (50 cc) This method is used only when changing the main frame, with the removal of several assemblies When changing the frame due to an accident, the method must be completed by the repair or replacement of damaged items

-

Remove the passenger seat

-

Remove the battery cover

-

Disconnect and remove the battery

-

Remove the rear shield panel (see procedure

3)

-

Remove the handlebar front and rear covers

-

Remove the fork guard

-

Remove the mudguard

-

Unclip and disconnect the main harness from

the front part of the machine, and from the components around the engine

- Disconnect the separate lubrication oil pipe from the engine casing

- Remove the frame 4 fixing bolts

- Remove the complete rear frame with the main harness

- Remove the front caliper and braking limit but do not disconnect them

- Remove the handlebar assembly without disconnecting the hydraulic controls

- Remove the radiator/bracket/header tank assembly

assembly without disconnecting the hydraulic controls - Remove the radiator/bracket/header tank assembly Page : 27
assembly without disconnecting the hydraulic controls - Remove the radiator/bracket/header tank assembly Page : 27
assembly without disconnecting the hydraulic controls - Remove the radiator/bracket/header tank assembly Page : 27
assembly without disconnecting the hydraulic controls - Remove the radiator/bracket/header tank assembly Page : 27

Page : 27

FRAME

- Disconnect the fuel tank sender unit return

pipe

- Using tool part number 755996 clamp the fuel

supply hose between the tank and the fuel pump

- Remove the fuel tank

- Remove the saddle pivot

- Remove the high voltage coil

- Remove the shock absorber upper mount

- Remove the swingarm to frame mount

- Pull back the power unit

- Remove the fork assembly with the wheel

Note: Self-lubricating captive balls are fitted in the lower race

- Remove the remaining items from the frame,

cage nuts, plastic inserts, ignition key switch,

manufacturer’s plate, lower cover brackets, steering cups

cage nuts, plastic inserts, ignition key switch, manufacturer’s plate, lower cover brackets, steering cups Page :
cage nuts, plastic inserts, ignition key switch, manufacturer’s plate, lower cover brackets, steering cups Page :
cage nuts, plastic inserts, ignition key switch, manufacturer’s plate, lower cover brackets, steering cups Page :

Page : 28

cage nuts, plastic inserts, ignition key switch, manufacturer’s plate, lower cover brackets, steering cups Page :

MISCELLANEOUS OPERATIONS

MISCELLANEOUS OPERATIONS Removal of the oil tank (50 cc) or oil separator (125 cc), the saddle lock (50 and 125 cc)

- Remove the rear cover assembly (see procedure

4)

- Unclip the harness from the battery bracket

without disconnecting the components

- Remove the battery cover

- Disconnect and remove the battery

- Remove the battery bracket

- Disconnect the oil level low switch

- Disconnect the oil pump

- Remove the oil tank (1) and/or the saddle lock

(2)

Note: When refitting the oil tank ensure there are no air bubbles in the pump feed pipe before connecting it

To remove the oil filter (50 cc)

- Remove the storage compartment (see procedure 2)

- Remove the oil filter (1)

Note: When refitting ensure there are no air bubbles in the oil filter in its feed pipes before reconnecting the to the oil pump

To remove the header tank (50 and 125 cc)

- Remove the front lower legshields (see procedure 1)

- Drain the cooling system

- Disconnect the header tank pipes

- Remove the upper fixing bolts

- Clear the header tank (1) from the bracket guides and rear shield

- Remove the header tank

Note: When refitting, locate the header tank positioning pins (A) and the window (B) in the rear shield and in the radiator bracket

locate the header tank positioning pins (A) and the window (B) in the rear shield and
locate the header tank positioning pins (A) and the window (B) in the rear shield and
locate the header tank positioning pins (A) and the window (B) in the rear shield and
locate the header tank positioning pins (A) and the window (B) in the rear shield and

Page : 29

MISCELLANEOUS OPERATIONS

Removal of the radiator / radiator bracket (50 and 125 cc)

- Remove the front lower legshields (see

procedure 1)

- Remove the rear shield panel (see procedure

3)

- Remove the fork guard (1) 2 fixing bolts

without removing the guard

- Remove the mudguard (2)

- Drain off the coolant

- Disconnect the radiator cooling system 4 pipes (3)

- Remove the radiator (4) (4 bolts)

- Unclip the deflector (5)

- Disconnect the horn and immobiliser unit

- Unclip the harness

- Remove the radiator bracket (3 bolts) with its components (immobiliser unit, horn and header tank)

harness - Remove the radiator bracket (3 bolts) with its components (immobiliser unit, horn and header
harness - Remove the radiator bracket (3 bolts) with its components (immobiliser unit, horn and header

Page : 30

harness - Remove the radiator bracket (3 bolts) with its components (immobiliser unit, horn and header

MISCELLANEOUS OPERATIONS

Removal of the fuel gauge (50 cc)

- Remove the storage compartment (see

procedure 2)

- Remove the tank cover panel (5 screws)

- Remove the saddle pivot bracket

(2 nuts)

- Disconnect the fuel gauge (1)

- Disconnect the return and vent pipes (2) from the sender unit

- Unscrew and remove the fuel sender unit and its seal using plug wrench part number 756716

Reassembly: Re-assemble in the reverse order to dismantling

- Tighten the fuel sender unit using plug

wrench part number 756716 in order to position the arrow (A) between the marks (B) on the tank

unit using plug wrench part number 756716 in order to position the arrow (A) between the
unit using plug wrench part number 756716 in order to position the arrow (A) between the
unit using plug wrench part number 756716 in order to position the arrow (A) between the
unit using plug wrench part number 756716 in order to position the arrow (A) between the

Page : 31

MISCELLANEOUS OPERATIONS

Removal of the strainer (50 cc)

- Remove the storage compartment (see

procedure 2)

- Remove the tank cover panel (5 screws)

- Remove the saddle pivot bracket (2 nuts)

- Remove the footboard and the left tunnel

- Disconnect the fuel gauge (1)

- Disconnect the vent pipe (2) from the sender

unit and put into a container in order to drain the

tank

- Disconnect the return pipe (3) from the sender

unit

- Unscrew and remove the sender unit and its seal using tool 756716

- Remove the strainer (4) by passing one hand

inside the sender unit, wearing a protective glove

- Clean or change the strainer in accordance with the service instructions

Note: When refitting tighten the sender unit using tool part number 756716 as described above

instructions Note: When refitting tighten the sender unit using tool part number 756716 as described above
instructions Note: When refitting tighten the sender unit using tool part number 756716 as described above

Page : 32

instructions Note: When refitting tighten the sender unit using tool part number 756716 as described above

MISCELLANEOUS OPERATIONS

Removal of the fuel tank filler ring (50 and 125 cc)

- Remove the storage compartment (see procedure 2)

- Remove the tank filler cap (3 screws)

- Remove the filler cap trim

- Remove the tank cover panel (5 screws)

- Remove the tank filler ring (1) (3 screws)

Note: Mark the fitting position of the filler ring on the tank The filler ring is clipped into the tank, the assembly is sealed by 2 O-rings (2) When removing the trim 3 screws, take care not to release the 3 nuts held in place in the tank filler ring

Removal of the fuel tank (50 cc)

- Remove the front lower legshield assembly

(see procedure 1)

- Remove the rear shield panel (see procedure

3)

- Remove the radiator / deflector / bracket

assembly

- Remove the injection manifold

- Using the injector actuator, drop the fuel

pressure in the circuit (see procedure 6)

- Disconnect the fuel gauge (1)

- Disconnect the return pipe (2) from the sender

unit

- Disconnect the fuel gauge (3)

- Disconnect the pump (4) from its bracket

- Disconnect the fuel pump output hose (5)

the fuel gauge (3) - Disconnect the pump (4) from its bracket - Disconnect the fuel
the fuel gauge (3) - Disconnect the pump (4) from its bracket - Disconnect the fuel
the fuel gauge (3) - Disconnect the pump (4) from its bracket - Disconnect the fuel
the fuel gauge (3) - Disconnect the pump (4) from its bracket - Disconnect the fuel

Page : 33

MISCELLANEOUS OPERATIONS

- Remove the tank upper fixing bolts (6)

- Remove the tank to frame 2 fixing brackets

(7)

- Remove the tank with the fixing lugs, the fuel pump, the feed hoses and the cap

Removal of the central shock absorber / from the swingarm (50 and 125 cc)

- Remove the storage compartment (see procedure 2)

- Remove the tank cover panel (5 screws)

- Remove the footboard (4 screws)

- Remove the tunnels (4 screws)

- Remove the bottom panels (7 bis)

- Remove the saddle pivot bracket (1)

(2 nuts)

- Remove the shock absorber upper mount (2)

- Remove the linkrod to swingarm (4) mount

(3)

- Remove the shock absorber lower mount (5)

- Remove the shock absorber

- Remove the swingarm to frame mount (6)

- Remove the swingarm

Note: We recommend greasing all needle bearings when refitting these parts

mount (6) - Remove the swingarm Note: We recommend greasing all needle bearings when refitting these
mount (6) - Remove the swingarm Note: We recommend greasing all needle bearings when refitting these
mount (6) - Remove the swingarm Note: We recommend greasing all needle bearings when refitting these

Page : 34

mount (6) - Remove the swingarm Note: We recommend greasing all needle bearings when refitting these

MISCELLANEOUS OPERATIONS

Removal of the radiator deflector (50 cc)

- Remove the footboards (4 screws)

- Remove the tunnels (4 screws)

- Remove the bottom panels (7 bis)

- Unclip the deflector (1) from the radiator bracket and pull it downwards

Removal of the braking limiter (50 cc)

- Remove the footboards (4 screws)

- Remove the tunnels (4 screws)

- Remove the bottom panels (7 bis)

- Remove the limiter fixing bolts (1)

- Disconnect and remove the limiter

Note: The braking system should be bled each time the limiter is worked on

Removal of the saddle strut (50 and 125 cc)

- Remove the storage compartment (see procedure 2)

- Remove the saddle strut lower mount (1)

- Remove the saddle strut

Note: Note the position of the saddle strut on the storage compartment

mount (1) - Remove the saddle strut Note: Note the position of the saddle strut on
mount (1) - Remove the saddle strut Note: Note the position of the saddle strut on
mount (1) - Remove the saddle strut Note: Note the position of the saddle strut on
mount (1) - Remove the saddle strut Note: Note the position of the saddle strut on

Page : 35

WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE

WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE (50 cc)

Removal of the inlet coupling and valves

- Remove the transmission cover strip (1 screw)

- Remove the air filter housing (2 screws)

- Disconnect the throttle cable (1) from the throttle unit

- Disconnect the throttle unit (2)

- Remove the inlet coupling 2 fixing bolts

- Remove the inlet coupling and the throttle unit (3)

- Remove the clip from the throttle unit

- Remove the inlet coupling

- Remove the valves and paper gasket (4)

Reassembly: Re-assemble in the reverse order to dismantling

Check: Using the diagnostic tool, check for fault codes, clear them if necessary

order to dismantling Check : Using the diagnostic tool, check for fault codes, clear them if
order to dismantling Check : Using the diagnostic tool, check for fault codes, clear them if

Page : 36

order to dismantling Check : Using the diagnostic tool, check for fault codes, clear them if

WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE

To remove the cylinder head Procedure 5

- Remove the footboards (4 screws)

- Remove the tunnels (4 screws)

- Remove the bottom panels (7 bis)

- Disconnect the lower pump from the coolant pump to drain the cooling system

- Disconnect the coolant pipes from the

cylinder head and cylinder

- Remove the injection manifold (1) (2 bolts)

- Disconnect the air injector (2), the

temperature sensor and suppressor

- Remove the spark plug

- Working diagonally a few turns at a time,

slacken the cylinder head/cylinder assembly

fixing bolts

- Remove the 4 bolts

- Remove the cylinder head and the O-ring

Note: Make sure to block the cylinder in the engine casing in order to avoid damage to the base gasket Do not remove the air injector if this is not necessary

Removal of the cylinder / piston

- Remove the storage compartment (see

procedure 2)

- Remove the exhaust

- Remove the cylinder head (see procedure 4)

- Remove the cylinder and the bottom seal

- Remove the piston

Note: When refitting the cylinder, we recommend locking the piston using the fork part number 756575 in order to facilitate assembly

cylinder, we recommend locking the piston using the fork part number 756575 in order to facilitate
cylinder, we recommend locking the piston using the fork part number 756575 in order to facilitate
cylinder, we recommend locking the piston using the fork part number 756575 in order to facilitate
cylinder, we recommend locking the piston using the fork part number 756575 in order to facilitate

Page : 37

WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE

Removal of the temperature sensor

- Remove the storage compartment (see

procedure 2)

- Disconnect the temperature sensor (1)

- Remove the sensor

Note: Refit a sensor quickly to prevent loss of coolant

Removal of the air compressor

- Remove the transmission cover strip (1 screw)

- Remove the air filter housing (2 screws)

- Remove the compressor (1) 4 bolts

- Remove the compressor with its hose

- Remove the clip from the pipe (2)

- Remove the compressor

Note: On refitting, fit the compressor with its 2 centring studs and a new lightly greased O-ring Tighten the 4 fixing bolts working diagonally a few turns at a time

studs and a new lightly greased O-ring Tighten the 4 fixing bolts working diagonally a few
studs and a new lightly greased O-ring Tighten the 4 fixing bolts working diagonally a few
studs and a new lightly greased O-ring Tighten the 4 fixing bolts working diagonally a few

Page : 38

studs and a new lightly greased O-ring Tighten the 4 fixing bolts working diagonally a few

SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE

SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE Procedure for reducing the fuel circuit pressure Procedure 6 (50 cc) Important: Wash the power unit

- Remove the footboards (4 screws)

- Remove the tunnels (4 screws)

- Remove the bottom panels (7 bis)

- Disconnect the fuel injector (1)

- Remove the 2 bolts from the injection

manifold (2)

- Remove the injection manifold without disconnecting the feed pipes

- Connect the fuel injector power supply

harness tool P/N 756017 to the fuel injector and the battery

- Put the manifold into a container to recover the fuel

- Operate the tool contactor 5 times for 5

seconds with a 5 second pause between each operation, in order to lower the pressure in the injection manifold supply pipe

Note: Secure the injection manifold in the container, the pressurised jet of fuel may be dangerous for the skin, do not expose the hands to the jet of fuel when opening the injector

Procedure for bleeding the fuel circuit Procedure 7 (50 and 125 cc)

- Operate the fuel pump by turning the key to

the ignition position (turning on the ignition operates the fuel pump for 3 seconds)

- Carry out this operation twice

position (turning on the ignition operates the fuel pump for 3 seconds) - Carry out this
position (turning on the ignition operates the fuel pump for 3 seconds) - Carry out this
position (turning on the ignition operates the fuel pump for 3 seconds) - Carry out this

Page : 39

SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE

Removal of the injection manifold (50 cc) Important: Wash the power unit

- Carry out the procedure used to lower the

pressure in the fuel system (see instruction 6)

- Remove the clips from the 3 hoses (each time

these clips are removed they must be changed for new genuine parts

- Disconnect the 2 fuel pipes (1)

- Disconnect the air pipe (2) from the compressor

- Remove the injection manifold (3)

- Remove the O-ring (4) from under the

injection manifold (the O-ring must be renewed

each time it is removed)

Reassembly: Proceed in reverse order to disassembly and bleed the fuel system (see instruction 7)

Removal of the air injector (50 cc)

- Remove the cylinder head (see procedure 5)

- Drift out the air injector (1) with drift part number 755989

- Remove the O-ring from under the air injector (the O-ring must be renewed each time it is removed)

755989 - Remove the O-ring from under the air injector (the O-ring must be renewed each
755989 - Remove the O-ring from under the air injector (the O-ring must be renewed each
755989 - Remove the O-ring from under the air injector (the O-ring must be renewed each

Page : 40

755989 - Remove the O-ring from under the air injector (the O-ring must be renewed each

SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE

Important: Put the injector in the holder tool P/N 755986 until ready for refitting

Note: The injector may only be removed for a short instant from its housing in the cylinder head, as the air injector has a Teflon seal which expands if it is not held compressed

Reassembly: Re-assemble in the reverse order to dismantling

Check: Using the diagnostic tool, check for fault codes, clear them if necessary

Removal of the thermostat (50 cc)

- Remove the cylinder head (see procedure 5)

- Remove the circlip (1) from the thermostat (2)

- Remove the thermostat

When refitting, make sure the thermostat (2) circlip (1) is correctly fitted, as shown

Note: The thermostat circlip must be changed each time it is removed

circlip (1) is correctly fitted, as shown Note: The thermostat circlip must be changed each time
circlip (1) is correctly fitted, as shown Note: The thermostat circlip must be changed each time
circlip (1) is correctly fitted, as shown Note: The thermostat circlip must be changed each time
circlip (1) is correctly fitted, as shown Note: The thermostat circlip must be changed each time

Page : 41

SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE

Removal of the ECU (50 and 125 cc)

- Remove the storage compartment (see procedure 2)

- Remove the ignition key

- Remove the ECU two fixing nuts

- Remove and disconnect the ECU (1)

Important: If the ECU is changed, the throttle unit must be initialised with the diagnostic tool (refer to diagnostic tool user documentation for the injection engine)

Removal of the throttle unit (50 cc)

- Remove the transmission cover strip (1 screw)

- Remove the air filter housing (2 screws)

- Disconnect the throttle cable (1) from the throttle unit

- Disconnect the throttle unit (2)

- Remove the inlet coupling 2 fixing bolts

- Remove the inlet coupling and the throttle unit

- Remove the clip from the throttle unit

- Remove the throttle unit

Important: If the throttle unit is changed it must be initialised with the diagnostic tool (refer to the diagnostic tool user documentation for the injection engine)

Check: Using the diagnostic tool, check for fault codes, clear them if necessary

Reassembly: Proceed in reverse order to disassembly ensuring:

- the throttle unit positioning pin (A) is properly located in its housing (B) on the inlet coupling

- the throttle cable is properly tensioned

- the throttle unit is properly positioned on the air filter box

- the throttle cable is properly tensioned - the throttle unit is properly positioned on the
- the throttle cable is properly tensioned - the throttle unit is properly positioned on the
- the throttle cable is properly tensioned - the throttle unit is properly positioned on the

Page : 42

- the throttle cable is properly tensioned - the throttle unit is properly positioned on the

SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE

Removal of the oil pump (50 cc)

- Remove the storage compartment (see

procedure 2)

- Disconnect the engine casing separate lubrication pipe

- Disconnect the oil pump (1)

- Remove the oil pump fixing bolt

- Disconnect the oil inlet pipe (2) from the pump

- Remove the oil pump

Important: Using the diagnostic tool bleed the oil pump (refer to the diagnostic tool user documentation for the injection engine)

Check: Using the diagnostic tool, check for fault codes, clear them if necessary

Removal of the fuel gauge (50 cc)

- Remove the footboards (2 screws each)

- Remove the tunnels (3 screws each)

- Carry out the procedure used to lower the

pressure in the fuel system (see instruction 6)

- Disconnect the fuel gauge (1)

- Remove the fuel pump (2) from its mounting

- Clamp the fuel inlet hose with the hose clamp

part number 755996

- Disconnect the fuel inlet and outlet hoses (3)

- Remove the fuel pump

with the hose clamp part number 755996 - Disconnect the fuel inlet and outlet hoses (3)
with the hose clamp part number 755996 - Disconnect the fuel inlet and outlet hoses (3)
with the hose clamp part number 755996 - Disconnect the fuel inlet and outlet hoses (3)

Page : 43

ELECTRICITY

ELECTRICITY Removal of the instrument cluster (50 and 125 cc)

- Remove the front upper legshield (3 screws)

- Remove the screen (depending on version)

- Remove the handlebar front cover (6 bolts)

- Remove the handlebar rear cover and instrument cluster (1) assembly (3 bolts)

- Disconnect the instrument cluster (2)

- Remove the instrument cluster (4 bolts)

Note: When refitting, carefully connect the harness to the instrument cluster, with the rubber cover on the connector and correctly position the harness securing clip (A)

Removal of the voltage regulator and saddle actuator (50 and 125 cc)

- Remove the storage compartment (see

procedure 2)

- Remove the regulator (1) or the saddle actuator (2)

Note: When refitting the voltage regulator carefully connect the connector and its cover before fitting to the frame

Removal of the battery cover, battery, fuses (50 and 125 cc)

- Remove the passenger seat (2 bolts)

- Remove the battery cover (1) (1 bolt)

- Remove the battery and/or change the fuses

passenger seat (2 bolts) - Remove the battery cover (1) (1 bolt) - Remove the battery
passenger seat (2 bolts) - Remove the battery cover (1) (1 bolt) - Remove the battery
passenger seat (2 bolts) - Remove the battery cover (1) (1 bolt) - Remove the battery

Page : 44

passenger seat (2 bolts) - Remove the battery cover (1) (1 bolt) - Remove the battery

ELECTRICITY

Removal of the starter motor and/or lighting relay (50 and 125 cc) and/or the fuel pump and/or ABS/PBS system relay (125 cc)

-

Remove the rear cover assembly (see procedure

4)

-

Remove the relay concerned

lighting relay (1) (50 and 125 cc) and fuel pump relay (125 c)

-

starter motor relay (2) (50 cc) (on the 125 cc the relay is on the other side

-

ABS/PBS system relay (depending on version)

-

Removal of the high tension coil (50 and 125

cc)

-

Remove the left footboard (2 screws)

-

Remove the left tunnel (2 screws)

-

Remove the 2 coil fixing bolts (1)

-

Disconnect the coil (2) and the spark plug

lead

- Remove the high tension coil

Removal of the horn, immobiliser module (50 and 125 cc)

- Remove the front legshield assembly (see

procedure 1)

- On the 50 cc, the horn is mounted to the right of the radiator support bracket

- On the 125 cc, the horn is mounted on the front legshield support bracket

Note: If the immobiliser module is changed, the key programming procedure must be carried out

support bracket Note: If the immobiliser module is changed, the key programming procedure must be carried
support bracket Note: If the immobiliser module is changed, the key programming procedure must be carried
support bracket Note: If the immobiliser module is changed, the key programming procedure must be carried
support bracket Note: If the immobiliser module is changed, the key programming procedure must be carried

Page : 45

ELECTRICITY

Removal of the transponder antenna (50 and 125 cc)

- Remove the front lower legshields (see

procedure 1)

-

Remove the rear shield panel (see procedure

3)

-

Unclip the antenna (1) from the steering lock

Disconnect the antenna from the transponder module

-

- Remove the antenna from the transponder

Removal of the starter motor (50 cc)

- Remove the storage compartment (see procedure 2)

- Disconnect the starter motor

- Remove the starter motor (1) 2 bolts

- Remove the starter motor

procedure 2) - Disconnect the starter motor - Remove the starter motor (1) 2 bolts -
procedure 2) - Disconnect the starter motor - Remove the starter motor (1) 2 bolts -

Page : 46

procedure 2) - Disconnect the starter motor - Remove the starter motor (1) 2 bolts -

ENGINE REMOVAL

ENGINE REMOVAL Removal of the 50 cc engine

Important: Wash the power unit

- Remove the storage compartment

- Remove the passenger seat

- Remove the battery cover

- Disconnect the battery

- Remove the 2 footboards

- Remove the 2 tunnels

- Remove the lower panel

- Remove the transmission cover strip

- Remove the air filter unit

- Drain off the cooling system at the water pump hoses

- Disconnect:

- the magneto

- the starter motor

- the throttle unit

- the air injector

- the suppressor

- the temperature sensor

- the throttle cable

- the crankcase separate lubricating oil inlet

- Remove the injection manifold without disconnecting the fuel supply pipes (see relevant chapter), however disconnect the compressor air pipe

- Pull clear the injection manifold and protect it from foreign matter with a clean rag

- Remove the exhaust

- Slacken off the wheel hub nut

- Remove the wheel

- Remove the 2 brake calipers but do not disconnect them

- Remove the disc/hub assembly

- Suspend the rear of the machine

- Remove the linkrod to swingarm fixing pin

- Remove the engine mounting upper pin

- Remove the engine / stand / linkrod assembly

- Remove the linkrod

- Remove the stand

- Remove the engine upper mount bush

engine / stand / linkrod assembly - Remove the linkrod - Remove the stand - Remove

Page : 47

125 cc SPECIFIC MISCELLANEOUS WORK

125 cc SPECIFIC MISCELLANEOUS WORK

Removal of the idle valve

- Disconnect the battery

- Disconnect the fuel injector (1)

- Disconnect the idle valve (2)

- Disconnect the idle valve two hoses (3)

- Remove the idle valve (4)

Removal of the thermostat

- Remove the storage compartment (see procedure 2)

- Disconnect the battery

- Disconnect the idle valve (1)

- Disconnect the engine casing cooling system inlet pipe in order to drain the system

- Remove the top (2) from the thermostat (2 screws) without disconnecting the hose

- Remove the thermostat

Note: After refitting, bleed the engine circuit hot and check the coolant level in the header tank (Peugeot approved coolant)

Removal of the engine temperature sensor

- Remove the storage compartment (see

procedure 2)

- Disconnect the battery

- Disconnect the fuel injector and the idle valve

- Disconnect the temperature sensor (1)

- Disconnect the engine casing cooling system inlet pipe in order to drain the system

- Remove the sensor (1) and its seal

Note: The seal must be changed each time it is removed After refitting, bleed the engine circuit hot and check the coolant level in the header tank

it is removed After refitting, bleed the engine circuit hot and check the coolant level in
it is removed After refitting, bleed the engine circuit hot and check the coolant level in
it is removed After refitting, bleed the engine circuit hot and check the coolant level in

Page : 48

it is removed After refitting, bleed the engine circuit hot and check the coolant level in

125 cc SPECIFIC MISCELLANEOUS WORK

Removal of the fuel injector

- Remove the storage compartment (see procedure 2)

- Disconnect the battery

- Disconnect the fuel injector (1)

- Disconnect the fuel feed hose (2) (1 clip, to be changed each time it is removed)

- Remove the fuel injector (3) (1 bolt)

Inspection: Connect the diagnostic tool and check there are no fault codes, erase them if necessary

Removal of the oil pressure switch

- Remove the exhaust elbow (1) (2 bolts and 2

nuts)

- Disconnect the pressure switch (2)

- Remove the cylinder to casing fixing bolt (3)

- Remove the oil pressure switch (2) and its seal

Removal of the throttle unit

- Remove the storage compartment (see

procedure 2)

- Disconnect the battery

- Disconnect the atmospheric pressure sensor

(1)

- Disconnect the oil vapour return pipe (2)

- Remove the air filter housing (3) (2 bolts)

pressure sensor (1) - Disconnect the oil vapour return pipe (2) - Remove the air filter
pressure sensor (1) - Disconnect the oil vapour return pipe (2) - Remove the air filter
pressure sensor (1) - Disconnect the oil vapour return pipe (2) - Remove the air filter
pressure sensor (1) - Disconnect the oil vapour return pipe (2) - Remove the air filter

Page : 49

125 cc SPECIFIC MISCELLANEOUS WORK

- Disconnect the throttle unit and the idle valve

- Remove the throttle cable

- Remove the throttle unit with the idle valve (1 clip, to be changed each time it is removed)

Important: If the throttle unit is changed it must be initialised with the diagnostic tool (refer to the diagnostic tool user documentation for the injection engine)

Reassembly: Proceed in reverse order to disassembly ensuring:

- the throttle unit positioning pin (A) is properly located in its housing (B) on the inlet coupling

- the throttle cable is properly tensioned

- the throttle unit is properly positioned on the air filter box

Inspection: Connect the diagnostic tool and check there are no fault codes, erase them if necessary

box Inspection: Connect the diagnostic tool and check there are no fault codes, erase them if
box Inspection: Connect the diagnostic tool and check there are no fault codes, erase them if

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box Inspection: Connect the diagnostic tool and check there are no fault codes, erase them if

125 cc SPECIFIC MISCELLANEOUS WORK

Removal of the fuel pump / of the fuel gauge

- Remove the storage compartment (see

procedure 2)

- Remove the tank cover panel (5 screws)

- Remove the saddle pivot bracket (1) (2 nuts)

- Remove the ignition key

- Disconnect the fuel gauge (2)

- Disconnect the fuel gauge (3)

Note: Put a rag over the fuel pipe to catch any fuel splashes

- Disconnect the fuel feed pipe (4) and the regulator vacuum pipe (5)

- Remove the fuel gauge with its seal using the

gauge wrench part number 756715 (and press on the tool in order to squash the rubber seal and unscrew one quarter of a turn)

- Unscrew and remove the fuel pump assembly with its seal using tool P/N 756716

Note: None of the components, fuel pump, pressure regulator and strainer are removable It is only possible to clean the outside of the strainer

pump, pressure regulator and strainer are removable It is only possible to clean the outside of
pump, pressure regulator and strainer are removable It is only possible to clean the outside of
pump, pressure regulator and strainer are removable It is only possible to clean the outside of
pump, pressure regulator and strainer are removable It is only possible to clean the outside of

Page : 51

125 cc SPECIFIC MISCELLANEOUS WORK

Reassembly: Re-assemble in the reverse order to dismantling

- Tighten the fuel pump using the plug wrench

P/N 756716 in order to position the arrow (A) between the marks (B) on the tank

- Fit the fuel gauge with a new seal using the gauge wrench P/N 756715

Inspection: Connect the diagnostic tool and check there are no fault codes, erase them if necessary

Removal of the starter motor

- Disconnect the atmospheric pressure sensor

- Disconnect the oil vapour return hose

- Remove the air filter housing (2 screws)

- Disconnect the battery

- Disconnect the starter motor (1)

- Remove the starter motor (2) (2 bolts)

Note: One of the starter motor fixing bolts is used for the battery engine earth (green wire)

(2) (2 bolts) Note: One of the starter motor fixing bolts is used for the battery
(2) (2 bolts) Note: One of the starter motor fixing bolts is used for the battery

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(2) (2 bolts) Note: One of the starter motor fixing bolts is used for the battery

125 cc SPECIFIC MISCELLANEOUS WORK

Removal of the rear brake pads or caliper

- Remove the pad 2 fixing pins

- Remove the caliper 2 fixing bolts

- Pull the caliper onto the disc to release the pads (1)

- Remove the brake pads

Note: After removing the pads, the caliper may be removed from the brake disc. If the caliper is to be changed, the hydraulic control must be slackened off before removal

Removal of the suspension arm

- Remove the exhaust (3 bolts and 2 bolts nuts)

- Remove the wheel spindle nut and the 2 washers

- Remove the suspension arm (1) to casing 2 fixing bolts

- Remove the suspension arm

Note: For re-assembly proceed in reverse order to removal as shown in the diagram

1. Suspension arm

2. Wheel spindle nut

3. Plain washer

4. Bearing flanges

5. Bush

as shown in the diagram 1. Suspension arm 2. Wheel spindle nut 3. Plain washer 4.
as shown in the diagram 1. Suspension arm 2. Wheel spindle nut 3. Plain washer 4.
as shown in the diagram 1. Suspension arm 2. Wheel spindle nut 3. Plain washer 4.
as shown in the diagram 1. Suspension arm 2. Wheel spindle nut 3. Plain washer 4.

Page : 53

125 cc SPECIFIC MISCELLANEOUS WORK

Removal of the engine mounting twin linkrod

- Remove the storage compartment (see procedure 2)

- Remove the left-hand footboard and tunnel

- Disconnect the battery

- Disconnect the oil vapour return pipe to the air filter

- Disconnect the atmospheric pressure sensor

- Remove the air filter unit

- Disconnect the starter motor, the idle valve and the fuel injector

- Disconnect the magneto harness and engine harness connections

- Slacken off the upper mounts (1) of the engine mounting twin linkrod (2)

- Slacken off and remove the twin linkrod lower securing pin (3)

Note: Suspend the machine or wedge it under the swingarm twin linkrod

- Remove the twin linkrod upper fixing pins

- Remove the twin linkrod and the 2 rubber bump stops (4)

linkrod - Remove the twin linkrod upper fixing pins - Remove the twin linkrod and the
linkrod - Remove the twin linkrod upper fixing pins - Remove the twin linkrod and the
linkrod - Remove the twin linkrod upper fixing pins - Remove the twin linkrod and the

Page : 54

linkrod - Remove the twin linkrod upper fixing pins - Remove the twin linkrod and the

125 cc SPECIFIC MISCELLANEOUS WORK

Method of fitting the engine mounting twin linkrod

- Fit the 2 rubber bump stops (1) to the frame

- Fit the twin linkrod (2) to the frame taking care it lines up with the rubber bump stops

- Fit the twin linkrod upper fixing pins (3)

- Fit the twin linkrod lower fixing pin (4)

the rubber bump stops - Fit the twin linkrod upper fixing pins (3) - Fit the
the rubber bump stops - Fit the twin linkrod upper fixing pins (3) - Fit the
the rubber bump stops - Fit the twin linkrod upper fixing pins (3) - Fit the
the rubber bump stops - Fit the twin linkrod upper fixing pins (3) - Fit the

Page : 55

125 cc SPECIFIC MISCELLANEOUS WORK

Removal of the motor-driven fan heat switch

- Remove the front lower legshields (see procedure 1)

- Remove the rear shield panel (see procedure

3)

- Remove the fork guard (1) 2 fixing bolts without removing the guard

- Remove the mudguard (2)

- Drain off the coolant

- Disconnect the heat switch (1)

- Remove the heat switch

Removal of the motor-driven fan

- Remove the front lower legshields (see

procedure 1)

- Remove the rear shield panel (see procedure

3)

- Remove the fork guard (1) 2 fixing bolts without removing the guard

- Remove the mudguard (2)

- Disconnect the fan (3)

- Remove the header tank and the radiator but do not disconnect them

- Remove the fan

- Disconnect the fan (3) - Remove the header tank and the radiator but do not
- Disconnect the fan (3) - Remove the header tank and the radiator but do not
- Disconnect the fan (3) - Remove the header tank and the radiator but do not

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- Disconnect the fan (3) - Remove the header tank and the radiator but do not

125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL

125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL Removal of the power unit Procedure 8

- Remove the storage compartment

- Remove the left-hand footboard and tunnel

- Disconnect the battery

- Disconnect the oil vapour return pipe to the air filter

- Disconnect the atmospheric pressure sensor

- Remove the air filter unit

- Disconnect the starter motor, the idle valve and the fuel injector

- Disconnect the magneto harness and engine harness connections

- Disconnect the suppressor

- Disconnect the throttle cable from the throttle unit

- Disconnect the injector fuel feed hose

- Disconnect the cylinder head air hose

- Disconnect the oil vapour return hose to the rocker cover

- Disconnect the oil filler pipe

- Remove the pad fixing pins

- Remove the caliper 2 fixing bolts

- Rest the caliper on the disc to remove the

pads

- Remove the brake pads

- Remove the caliper from the brake disc

- Remove the hydraulic control from its guides on the engine casing

- Disconnect the engine casing coolant inlet pipe to drain the circuit

- Disconnect the coolant outlet to the thermostat

Note: Suspend or wedge the machine frame before removing the power unit

- Remove the engine 2 pins securing it to the frame linkrod and engine linkrod

- Remove the power unit from the frame

the engine 2 pins securing it to the frame linkrod and engine linkrod - Remove the
the engine 2 pins securing it to the frame linkrod and engine linkrod - Remove the

Page : 57

125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL

Removal of the engine Procedure 9

- Remove the power unit (see

procedure 8)

- Remove the complete exhaust system

- Remove the inlet coupling and the throttle unit

- Remove the suspension arm

- Remove the wheel hub assembly

- Remove the stand

Removal of the rocker cover, setting the rockers, removal of the camshaft, removal of the rockers

- Remove the power unit (see procedure 8) and refer to the FD1 ENGINE workshop manual

Removal of the cylinder head, removal of the cylinder and/or piston, removal of the

cylinder head or base gasket, removal of the timing chain, setting the timing

- Remove the power unit (see procedure 8)

- Remove the exhaust and refer to the FD1 ENGINE workshop manual

Removal of the connecting rod and/or LH bearing and/or changing the casings

- Remove the engine (see procedure 9) and refer to the FD1 ENGINE workshop manual

and/or changing the casings - Remove the engine (see procedure 9) and refer to the FD1

Page : 58

and/or changing the casings - Remove the engine (see procedure 9) and refer to the FD1
RECOMMENDS REF: 756739 For reasons of continuous improvement, Peugeot Motocycles reserv es the right to

RECOMMENDS

RECOMMENDS REF: 756739 For reasons of continuous improvement, Peugeot Motocycles reserv es the right to modify,
RECOMMENDS REF: 756739 For reasons of continuous improvement, Peugeot Motocycles reserv es the right to modify,

REF: 756739

For reasons of continuous improvement, Peugeot Motocycles reserves the right to modify, delete or add any part number quoted DC/PS/ATR printed in EU 02/2002 (photos non-contractual)

es the right to modify, delete or add any part number quoted DC/PS/ATR printed in EU